Probe Assembly

1. Probe Assembly

2. Probe Assembly Dismount • Dismount • Shut off main power and Air. • Remove Probe Cover • Unhook power connection to sensors

3. Probe Assembly Dismount • Unhook all airlines that go to the probes (X,V, AS, R, & T) • The First 2 steps will require cutting some zip ties. • Remove 3 Screws from the left side that hold probes into place • There are also 2 dowel pins that hold this in as well. • This should allow you to remove the probes from the machine.

4. Probe Assembly Dismount

5. Probe Assembly Dismount

6. Probe Assembly Dismount

7. Probe Assembly Mounting • Remounting of Probes • Start with mounting up 3 screws that hold probes to machine. • Start each one and tighten little by little on each to make sure all are going in evenly to set flush. • There are also 2 dowel pins to help this process.

8. Probe Assembly Mounting

9. Probe Assembly Mounting • Connect all 5 airlines (X, V, AS, R, & T) • “X” – This plugs into the X fitting connection on the probes that feeds the two small air cylinders. This functions to open the jaws. • “V” – This plugs into the V fitting connection on the probes that feeds the two small air cylinders. This functions to close the jaws. • “AS” – This plugs into the AS fitting connection. This is for the Pneumastatic system air flow. This feeds air to the air bearings and the locks on the probes for when loosing pressure. • “R” – This mounts to the large air cylinder to the top of the unit. This pushes the cylinder out or the probes to the down position. There is an adjustable restrictor here for speed pushing down. • “T” – This connection is on the bottom of the large air cylinder on the probes. This pushes the cylinder to the up position. Again there is a restrictor to adjust speed of the cylinder.

10. Probe Assembly Mounting

11. Probe Assembly Mounting

12. Probe Assembly Mounting • Plug in the sensor power on the probes.

13. Probe Assembly Mounting • Tie up using zip ties (not to the probe restrictors) check diagrams for how this is tied up.

14. Probe Assembly Mounting • Re-hook up air and power to the machine. • Double check the probes can move up and down with air and that the rotation at the magnet is ok and not catching. • Double check all sensors are working out ok. • Run the probe calibration and verify proper working order.

15. Probe Calibration • Probe Calibration • Mount the 58 mm disk (stepped) with the PDA (pattern duplicator adaptor) and put in the chuck of the machine. • Go to the tool screen and hit calibrate probes.

16. Probe Calibration • Calibration Process • When the probes start to move into position the first thing that happens are the probes run to the tilt plate. The probes clamp on this plate and move up and down to verify and check sensor placement of the probes. • If the probes do not properly catch the plate correctly then we may need to adjust placement of the probes (front to back Y) and left to right (X). • If the X or the Y need to be adjusted they can be by adjusting the values for the tilt probing on the Control L screen.

17. Probe Calibration • Probe Disk: • After checking the calibration on the tilt plate the probes move over to check the calibration disk. • The probes should catch on the thick part of the step disk and go through a revolution. • From here the machine will do a number of calibration drags to verify proper X, Y placement. • The drags should always start on the thick part of the disk and move to the thin but not fully fall off the calibration disk. (If it does go in too deep/shallow for the thick part or completely falls off the disk then we will need to make some adjustments to placement in the Control L screen).

18. Probe Calibration • Control L • Typically if you need to make and adjustment adjust the min X for catching the thicker part of the disk or the Max X for the position from falling off the disk. • If you adjust and calibrate probes once you accept the value at the end make sure you set back to below value for the min/max X which should always be a default.

19. Probe Calibration • Once the probe calibration is done then you should be given a Radius , X, & Y position offsets. Hit ok to accept.

20. Probe Assembly Breakdown • Probe Operation Lift • Main Lift air cylinder • This drives the entire probe assembly up and down in the machine. • It has a sensor for the probe all the way in the up position.

21. Probe Assembly Breakdown

22. Probe Assembly Breakdown

23. Probe Assembly Breakdown • This is fed using airlines R and T. • Line R pushes probes down. (opens air cylinder) • Line T pushes probes up. (closes air cylinder) • There are adjustable restrictors in line here. • Large arrow facing cylinder and small away from the cylinder. This allows you to adjust the flow rate for smooth operation. Moving probe Up adjust the flow on the top of the cylinder (next to line R) for moving Down adjust the flow restrictor at the bottom next to line T.

24. Probe Assembly Breakdown

25. Probe Assembly Breakdown • The air cylinder shaft end is in put in a U shaped holder so it is not fully locked in to keep more of a smooth motion. • It is locked into the shaft as a lock nut.

26. Probe Assembly Breakdown • Main Rail Slide & Linear Bearing • This allows the probe to move with the push/pull action of the main lift cylinder. • This is a main linear bearing going up/down on the main rail. • 4 screws hold in the main linear bearing.

27. Probe Assembly Breakdown • You will have to remove the top probe stop using the 2 screws and the bearing should slide off the rail. • Use bearing capture to keep ball bearings from flying all over the place. • Go in reverse to replace.

28. Probe Assembly Breakdown • Probe Operation (Forks/ C-body) • Two main air cylinders run the forks to open and close. • This runs off airline X to push open and airline V to close.

29. Probe Assembly Breakdown • Lower Fork and Cylinder

30. Probe Assembly Breakdown • Upper Fork and Cylinder :

31. Probe Assembly Breakdown • Cylinder Sensor • Both fork sensors have sensor to read position. • Sensor reads with signal in and signal. • Brown wire +24 V, Blue wire Signal. • The sensors read probes open position. • They can be adjusted if needs be by loosing the Phillips screw and you should be able to move the sensor up and down to the correct reading position.

32. Probe Assembly Breakdown

33. Probe Assembly Breakdown • Jaw Cylinder Flow: • The jaw cylinders have a flow adjustment for the probes flow. This is done by adjust the valve on the bottom of the upper jaw cylinder for the upper jaw and the flow adjustment valve on the top of the lower jaw cylinder.

34. Probe Assembly Breakdown Jaw adjustments

35. Probe Assembly Breakdown • Probe Tip Settings • Mount tip using screw in from the top and bottom tip from the bottom. (American standard screws) • Tighten side screws that hold them into place. • Make sure tip flat is away from you when mounted into the unit. • Set probe tip spacing • This space should be very close (preferably 0.20 to 0.30). • On inside of probes attached to the jaw bearings there is a screw and lock nut. • Adjust the top one most of the way in and lock into poison using lock-tite. • Adjust bottom screw and nut for spacing between the two.

36. Probe Assembly Breakdown

37. Probe Assembly Breakdown • Each bearing is connected to an air cylinder and spacing sensor. • Lower bearing is pushed down with cylinder • Upper fork bearing pulls up with air cylinder. • Spacing Sensor There is one mounted to each bearing so it can read the fork movement. They work like a variable resistor (potentiometer) reading 0 to 5 volts for the signal. This is transmitted to software and difference between the two spacing sensors reads for the probe spacing.

38. Probe Assembly Breakdown

39. Probe Assembly Breakdown • Safety hinge on probes • Probes hinge to avoid crash. • Magnet holds hinge together.